Fibrous structure and process for making same

ABSTRACT

Through-air dried (“TAD”) fibrous structures, especially TAD fibrous structures incorporated into sanitary tissue products, that comprise a short fiber furnish having a length of from about 0.4 mm to about 1.2 mm and a coarseness of from about 3.0 mg/100 m to about 7.5 mg/100 m, and processes for making such TAD fibrous structures are provided.

FIELD OF THE INVENTION

[0001] The present invention relates to fibrous structures, especiallyTAD (“TAD”) fibrous structures incorporated into sanitary tissueproducts such as facial tissue, toilet tissue and paper towels, thatcomprise a short fiber furnish comprising a short fiber having a lengthof from about 0.4 mm to about 1.2 mm and a coarseness of from about 3.0mg/100 m to about 7.5 mg/100 m, and processes for making such fibrousstructures.

BACKGROUND OF THE INVENTION

[0002] Typically, fibrous structures used for sanitary tissue productscontain two or more fiber furnishes. Such fibrous structures typicallycontain one furnish comprised of relatively long fibers, i.e. fiberswith length-weighted average fiber length exceeding about 2 mm. Thisfurnish is intended as reinforcement or strength generation within thesanitary tissue products. Additionally, the fibrous structures typicallyfurther comprise at least one relatively short fiber furnish, i.e.fibers having a fiber length less than about 1.2 mm. These short fibersimprove the softness of the sanitary tissue products since they arerelatively unbonded. The unbonded fibers allow free ends, which impart avelvety smoothness to the structure. See U.S. Pat. No. 4,300,981 toCarstens incorporated herein by reference for a disclosure of suchvelvety structures.

[0003] It is well known to those skilled in the art that the use of theshort fibers is limited however from the point of view that a certainminimum average fiber length of that furnish is required and from thepoint of view that there is a maximum rate of inclusion of that furnishrelative to the longer-fibered furnish or furnishes used in the sanitarytissue paper structure. This limitation is due to the fact that strengthis lost. A certain amount of strength is necessary to be present in theproduct for the manufacturer to be able to handle the web whichultimately is converted into the sanitary tissue product. It is alsonecessary that the user of the end product be provided with a certainamount of strength to prevent/inhibit fingers poking through the productduring use for example.

[0004] This problem with strength development is heightened when thetissue paper product is made by the so-called TAD papermaking process.This is because strength development is improved when the tissue paperweb is pressed against the surface of a Yankee dryer. In some TADprocesses, this pressing is changed from pressing over 100% of the area,typical of conventional non-TAD processes, to less than 50%, morepreferably even less than 40% of the surface. While the strengthdevelopment is surprisingly good, it necessarily suffers relative toconventional web making. Furthermore in some TAD processes, the Yankeedryer has been eliminated completely which obviously totally eliminatesthis means of strength generation.

[0005] Today's art limits the short-fibered furnish used in TADprocesses to greater than about 0.75 mm.

[0006] Inventors have now found that, when accompanied by low coarsenessand a physical property modifier which can comprise either a permanentwet strength agent or a chemical softening agent, surprisingly low fiberlength, i.e. less than about 1.2 mm fibers can be used in the productionand use of TAD tissue paper structures and realizing a softness benefitfrom such fibers which would not hereinbefore be predicted.

[0007] No prior art reference teaches a TAD fibrous structure comprisinga short fiber furnish comprising a short fiber having a length of fromabout 0.4 mm to about 1.2 mm and a coarseness of from about 3.0 mg/100 mto about 7.5 mg/100 m, and a physical property ingredient selected fromthe group consisting of permanent wet strength resins, chemicalsofteners and mixtures thereof.

SUMMARY OF THE INVENTION

[0008] The present invention provides a TAD fibrous structure thatcomprises a short fiber furnish and a physical property ingredientselected from the group consisting of permanent wet strength resins,chemical softeners and mixtures thereof.

[0009] In one aspect of the present invention, a TAD fibrous structurecomprising a short fiber furnish comprising a short fiber having alength of from about 0.4 mm to about 1.2 mm and a coarseness of fromabout 3.0 mg/100 m to about 7.5 mg/100 m, and a physical propertyingredient selected from the group consisting of permanent wet strengthresins, chemical softeners and mixtures thereof, is provided.

[0010] In another aspect of the present invention, a paper productcomprising a TAD fibrous structure according to the present invention isprovided.

[0011] In yet another aspect of the present invention, a sanitary tissueproduct comprising a TAD fibrous structure wherein the sanitary tissueproduct is selected from the group consisting of facial tissue products,toilet tissue products, paper towel products and mixtures thereof, isprovided.

[0012] In yet still another aspect of the present invention, a processfor making a through-air dried fibrous structure comprising the stepsof:

[0013] a. preparing a fibrous furnish comprising a short fiber furnishcomprising a short fiber having a length of from about 0.4 mm to about1.2 mm and a coarseness of from about 3.0 mg/100 m to about 7.5 mg/100m, by mixing the short fiber with water to form the short fiber furnish;

[0014] b. depositing the fibrous furnish on a foraminous forming surfaceto form an embryonic fibrous web;

[0015] c. adding a permanent wet strength resin to the fibrous furnishand/or the embryonic fibrous web; and

[0016] d. through-air drying said embryonic fibrous web such that thethrough-air dried fibrous structure is formed, is provided.

[0017] In even yet another aspect of the present invention, a processfor making a through-air dried, chemical softener-containing fibrousstructure comprising the steps of:

[0018] a. preparing a fibrous furnish comprising a short fiber furnishcomprising a short fiber having a length of from about 0.4 mm to about1.2 mm and a coarseness of from about 3.0 mg/100 m to about 7.5 mg/100m, by mixing the short fiber with water to form the short fiber furnish;

[0019] b. depositing the fibrous furnish on a foraminous forming surfaceto form an embryonic fibrous web;

[0020] c. through-air drying said embryonic fibrous web such that athrough-air dried fibrous structure is formed; and

[0021] d. applying a chemical softener to the fibrous furnish and/orembryonic fibrous web and/or through-air dried fibrous structure suchthat the through-air dried, chemical softener-containing fibrousstructure is formed, is provided.

[0022] All documents cited are, in relevant part, incorporated herein byreference; the citation of any document is not to be construed as anadmission that it is prior art with respect to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0023] “Fiber” as used herein means a elongate particulate having anapparent length greatly exceeding its apparent width, i.e. a length todiameter ratio of at least about 10. More specifically, as used herein,“fiber” refers to papermaking fibers. The present invention.contemplates the use of a variety of papermaking fibers, such as, forexample, natural fibers or synthetic fibers, or any other suitablefibers, and any combination thereof. Papermaking fibers useful in thepresent invention include cellulosic fibers commonly known as wood pulpfibers. Applicable wood pulps include chemical pulps, such as Kraft,sulfite, and sulfate pulps, as well as mechanical pulps including, forexample, groundwood, thermomechanical pulp and chemically modifiedthermomechanical pulp. Chemical pulps, however, may be preferred sincethey impart a superior tactile sense of softness to tissue sheets madetherefrom. Pulps derived from both deciduous trees (hereinafter, alsoreferred to as “hardwood”) and coniferous trees (hereinafter, alsoreferred to as “softwood”) may be utilized. The hardwood and softwoodfibers can be blended, or alternatively, can be deposited in layers toprovide a stratified web. U.S. Pat. No. 4,300,981 and U.S. Pat. No.3,994,771 are incorporated herein by reference for the purpose ofdisclosing layering of hardwood and softwood fibers. Also applicable tothe present invention are fibers derived from recycled paper, which maycontain any or all of the above categories as well as other non-fibrousmaterials such as fillers and adhesives used to facilitate the originalpapermaking.

[0024] In addition to the various wood pulp fibers, other cellulosicfibers such as cotton linters, rayon, and bagasse can be used in thisinvention. Synthetic fibers, such as polymeric fibers, can also be used.Elastomeric polymers, polypropylene, polyethylene, polyester,polyolefin, and nylon, can be used. The polymeric fibers can be producedby spunbond processes, meltblown processes, and other suitable methodsknown in the art.

[0025] The embryonic web can be typically prepared from an aqueousdispersion of papermaking fibers, though dispersions in liquids otherthan water can be used. The fibers are dispersed in the carrier liquidto have a consistency of from about 0.1 to about 0.3 percent. It isbelieved that the present invention can also be applicable to moistforming operations where the fibers are dispersed in a carrier liquid tohave a consistency less than about 50 percent, more preferably less thanabout 10%.

[0026] “Sanitary tissue product” as used herein means a soft, lowdensity (i.e. < about 0.15 g/cm3) web useful as a wiping implement forpost-urinary and post-bowel movement cleaning (toilet tissue), forotorhinolaryngolical discharges (facial tissue), and multi-functionalabsorbent and cleaning uses (absorbent towels).

[0027] “Weight average molecular weight” as used herein means the weightaverage molecular weight as determined using gel permeationchromatography according to the protocol found in Colloids and SurfacesA. Physico Chemical & Engineering Aspects, Vol. 162, 2000, pg. 107-121.

[0028] “Wet Burst Strength” as used herein is a measure of the abilityof a fibrous structure and/or a paper product incorporating a fibrousstructure to absorb energy, when wet and subjected to deformation normalto the plane of the fibrous structure and/or paper product. Wet burststrength may be measured using a Thwing-Albert Burst Tester Cat. No. 177equipped with a 2000 g load cell commercially available fromThwing-Albert Instrument Company, Philadelphia, Pa.

[0029] Wet burst strength is measured by taking eight (8) fibrousstructures according to the present invention and staking them in fourpairs of two (2) samples each. Using scissors, cut the samples so thatthey are approximately 228 mm in the machine direction and approximately114 mm in the cross machine direction, each two finished product unitsthick. First, age the samples for two (2) hours by attaching the samplestack together with a small paper clip and “fan” the other end of thesample stack by a clamp in a 107° C. (±3° C.) forced draft oven for 5minutes (±10 seconds). After the heating period, remove the sample stackfrom the oven and cool for a minimum of three (3) minutes beforetesting. Take one sample strip, holding the sample by the narrow crossmachine direction edges, dipping the center of the sample into a panfilled with about 25 mm of distilled water. Leave the sample in thewater four (4) (±0.5) seconds. Remove and drain for three (3) (±0.5)seconds holding the sample so the water runs off in the cross machinedirection. Proceed with the test immediately after the drain step. Placethe wet sample on the lower ring of a sample holding device of the BurstTester with the outer surface of the sample facing up so that the wetpart of the sample completely covers the open surface of the sampleholding ring. If wrinkles are present, discard the samples and repeatwith a new sample. After the sample is properly in place on the lowersample holding ring, turn the switch that lowers the upper ring on theBurst Tester. The sample to be tested is now securely gripped in thesample holding unit. Start the burst test immediately at this point bypressing the start button on the Burst Tester. A plunger will begin torise toward the wet surface of the sample. At the point when the sampletears or ruptures, report the maximum reading. The plunger willautomatically reverse and return to its original starting position.Repeat this procedure on three (3) more samples for a total of four (4)tests, i.e., four (4) replicates. Report the results as an average ofthe four (4) replicates, to the nearest g.

[0030] “Basis Weight” as used herein is the weight per unit area of asample reported in lbs/3000 ft² or g/m². Basis weight is measured bypreparing one or more samples of a certain area (m²) and weighing thesample(s) of a fibrous structure according to the present inventionand/or a paper product comprising such fibrous structure on a toploading balance with a minimum resolution of 0.01 g. The balance isprotected from air drafts and other disturbances using a draft shield.Weights are recorded when the readings on the balance become constant.The average weight (g) is calculated and the average area of the samples(m²). The basis weight (g/m²) is calculated by dividing the averageweight (g) by the average area of the samples (m²).

[0031] “Machine Direction” or “MD” as used herein means the directionparallel to the flow of the fibrous structure through the papermakingmachine and/or product manufacturing equipment.

[0032] “Cross Machine Direction” or “CD” as used herein means thedirection perpendicular to the machine direction in the same plane ofthe fibrous structure and/or paper product comprising the fibrousstructure.

[0033] “Total Dry Tensile Strength” or “TDT” of a fibrous structure ofthe present invention and/or a paper product comprising such fibrousstructure is measured as follows. One (1) inch by five (5) inch (2.5cm×12.7 cm) strips of fibrous structure and/or paper product comprisingsuch fibrous structure are provided. The strip is placed on anelectronic tensile tester Model 1122 commercially available from InstronCorp., Canton, Mass. in a conditioned room at a temperature of 73° F.±4°F. (about 28° C.±2.2° C.) and a relative humidity of 50%±10%. Thecrosshead speed of the tensile tester is 2.0 inches per minute (about5.1 cm/minute) and the gauge length is 4.0 inches (about 10.2 cm). TheTDT is the arithmetic total of MD and CD tensile strengths of thestrips.

[0034] “Caliper” as used herein means the macroscopic thickness of asample. Caliper of a sample of fibrous structure according to thepresent invention is determined by cutting a sample of the fibrousstructure such that it is larger in size than a load foot loadingsurface where the load foot loading surface has a circular surface areaof about 3.14 in². The sample is confined between a horizontal flatsurface and the load foot loading surface. The load foot loading surfaceapplies a confining pressure to the sample of 15.5 g/cm² (about 0.21psi). The caliper is the resulting gap between the flat surface and theload foot loading surface. Such measurements can be obtained on a VIRElectronic Thickness Tester Model II available from Thwing-AlbertInstrument Company, Philadelphia, Pa. The caliper measurement isrepeated and recorded at least five (5) times so that an average calipercan be calculated. The result is reported in millimeters.

[0035] “Apparent Density” or “Density” as used herein means the basisweight of a sample divided by the caliper with appropriate conversionsincorporated therein. Apparent density used herein has the units g/cm³.

[0036] “Softness” of a fibrous structure according to the presentinvention and/or a paper product comprising such fibrous structure isdetermined as follows. Ideally, prior to softness testing, the samplesto be tested should be conditioned according to Tappi Method #T4020M-88.Here, samples are preconditioned for 24 hours at a relative humiditylevel of 10 to 35% and within a temperature range of 22° C. to 40° C.After this preconditioning step, samples should be conditioned for 24hours at a relative humidity of 48% to 52% and within a temperaturerange of 22° C. to 24° C. Ideally, the softness panel testing shouldtake place within the confines of a constant temperature and humidityroom. If this is not feasible, all samples, including the controls,should experience identical environmental exposure conditions.

[0037] Softness testing is performed as a paired comparison in a formsimilar to that described in “Manual on Sensory Testing Methods”, ASTMSpecial Technical Publication 434, published by the American Society ForTesting and Materials 1968 and is incorporated herein by reference.Softness is evaluated by subjective testing using what is referred to asa Paired Difference Test. The method employs a standard external to thetest material itself. For tactile perceived softness two samples arepresented such that the subject cannot see the samples, and the subjectis required to choose one of them on the basis of tactile softness. Theresult of the test is reported in what is referred to as Panel ScoreUnit (PSU). With respect to softness testing to obtain the softness datareported herein in PSU, a number of softness panel tests are performed.In each test ten practiced softness judges are asked to rate therelative softness of three sets of paired samples. The pairs of samplesare judged one pair at a time by each judge: one sample of each pairbeing designated X and the other Y. Briefly, each X sample is gradedagainst its paired Y sample as follows:

[0038] 1. a grade of plus one is given if X is judged to may be a littlesofter than Y, and a grade of minus one is given if Y is judged to maybe a little softer than X;

[0039] 2. a grade of plus two is given if X is judged to surely be alittle softer than Y, and a grade of minus two is given if Y is judgedto surely be a little softer than X;

[0040] 3. a grade of plus three is given to X if it is judged to be alot softer than Y, and a grade of minus three is given if Y is judged tobe a lot softer than X; and, lastly:

[0041] 4. a grade of plus four is given to X if it is judged to be awhole lot softer than Y, and a grade of minus 4 is given if Y is judgedto be a whole lot softer than X.

[0042] The grades are averaged and the resultant value is in units ofPSU. The resulting data are considered the results of one panel test. Ifmore than one sample pair is evaluated then all sample pairs are rankordered according to their grades by paired statistical analysis. Then,the rank is shifted up or down in value as required to give a zero PSUvalue to which ever sample is chosen to be the zero-base standard. Theother samples then have plus or minus values as determined by theirrelative grades with respect to the zero base standard. The number ofpanel tests performed and averaged is such that about 0.2 PSU representsa significant difference in subjectively perceived softness.

[0043] “Ply” or “Plies” as used herein means an individual fibrousstructure optionally to be disposed in a substantially contiguous,face-to-face relationship with other plies, forming a multiple plyfibrous structure. It is also contemplated that a single fibrousstructure can effectively form two “plies” or multiple “plies”, forexample, by being folded on itself.

[0044] As used herein, the articles “a” and “an” when used herein, forexample, “an anionic surfactant” or “a fiber” is understood to mean oneor more of the material that is claimed or described.

[0045] All percentages and ratios are calculated by weight unlessotherwise indicated. All percentages and ratios are calculated based onthe total composition unless otherwise indicated.

[0046] Unless otherwise noted, all component or composition levels arein reference to the active level of that component or composition, andare exclusive of impurities, for example, residual solvents orby-products, which may be present in commercially available sources.

[0047] TAD Fibrous Structure:

[0048] The TAD fibrous structure of the present invention may comprise afibrous furnish comprising a short fiber furnish comprising a shortfiber having a length of from about 0.4 mm to about 1.2 mm and acoarseness of from about 3.0 mg/100 m to about 7.5 mg/100 m.

[0049] In addition to the short fiber, the TAD fibrous structure maycomprise a wet strength resin, preferably a permanent wet strengthresin. Also, in addition to the short fiber, the TAD fibrous structuremay comprise a chemical softener. The fibrous furnish used to make theTAD fibrous structure may further comprise a permanent wet strengthresin.

[0050] The short fibers having a length of from about 0.4 mm to about1.2 mm and a coarseness of from about 3.0 mg/100 m to about 7.5 mg/100 mmay be present in the TAD fibrous structure at a level of at least 10%by weight of the total fibers, and/or at a level of at least 20% up to100% by weight of the total fibers of the TAD fibrous structure.

[0051] In addition to the short fiber, the TAD fibrous structure of thepresent invention may include optional ingredients, which are describedin more detail below.

[0052] In addition to the short fiber furnish, the fibrous furnish ofthe present invention may further comprise a long fiber furnishcomprising a long fiber having a length of greater than 1.2 mm.Nonlimiting examples of these long fibers include fibers derived fromwood pulp. Other cellulosic fibrous pulp fibers, such as cotton linters,bagasse, etc., can be utilized and are intended to be within the scopeof this invention. Synthetic fibers, such as rayon, polyethylene andpolypropylene fibers, can also be utilized in combination with naturalcellulosic fibers. One exemplary polyethylene fiber that can be utilizedis Pulpex(R), available from Hercules, Inc. (Wilmington, Del.).

[0053] Applicable wood pulps include chemical pulps, such as Kraft,especially Northern Softwood Kraft (“NSK”), sulfite, and sulfate pulps,as well as mechanical pulps including, for example, groundwood,thermomechanical pulp and chemically modified thermomechanical pulp.Chemical pulps, however, are preferred since they impart a superiortactile sense of softness to tissue sheets made therefrom. Pulps derivedfrom both deciduous trees (hereafter, also referred to as “hardwood”)and coniferous trees (hereafter, also referred to as “softwood”) can beutilized. Also useful in the present invention are fibers derived fromrecycled paper, which can contain any or all of the above categories aswell as other non-fibrous materials such as fillers and adhesives usedto facilitate the original papermaking.

[0054] In addition to wood pulps, fibers may be produced/obtained fromvegetable sources such as corn (i.e., starch).

[0055] The TAD fibrous structures of the present invention are useful inpaper, especially sanitary tissue paper products in general, includingbut not limited to conventionally felt-pressed tissue paper; high bulkpattern densified tissue paper; and high bulk, uncompacted tissue paper.The tissue paper can be of a homogenous or multi-layered construction;and tissue paper products made therefrom can be of a single-ply ormulti-ply construction. The tissue paper may have a basis weight ofbetween about 10 g/m2 to about 65 g/m2, and a density of from about 0.6g/cc or less.

[0056] Conventionally pressed tissue paper and methods for making suchpaper are well known in the art. Such paper is typically made bydepositing a papermaking furnish on a foraminous forming wire, oftenreferred to in the art as a Fourdrinier wire. Once the furnsh isdeposited on the forming wire, it is referred to as a web. The web isdewatered by pressing the web and drying at elevated temperature. Theparticular techniques and typical equipment for making webs according tothe process just described are well known to those skilled in the art.In a typical process, a low consistency pulp furnish is provided from apressurized headbox. The headbox has an opening for delivering a thindeposit of pulp furnish onto the Fourdrinier wire to form a wet web. Theweb is then typically dewatered to a fiber consistency of between about7% and about 25% (total web weight basis) by vacuum dewatering andfurther dried by pressing operations wherein the web is subjected topressure developed by opposing mechanical members, for example,cylindrical rolls. The dewatered web is then further pressed and driedby a steam drum apparatus known in the art as a Yankee dryer. Pressurecan be developed at the Yankee dryer by mechanical means such as anopposing cylindrical drum pressing against the web. Multiple Yankeedryer drums can be employed, whereby additional pressing is optionallyincurred between the drums. The tissue paper structures that are formedare referred to hereafter as conventional, pressed, tissue paperstructures. Such sheets are considered to be compacted since the entireweb is subjected to substantial mechanical compressional forces whilethe fibers are moist and are then dried while in a compressed state.

[0057] The TAD fibrous structure may be made with a fibrous furnish thatproduces a single layer embryonic fibrous web or a fibrous furnish thatproduces a multi-layer embryonic fibrous web. One or more short fibersmay be present in a fibrous furnish with one or more long fibers.Further, one or more short fibers may be present in a furnish layer withone or more long fibers.

[0058] The TAD fibrous structures of the present invention and/or paperproducts comprising such TAD fibrous structures may have a basis weightof from about 12 g/m² to about 120 g/m² and/or from about 14 g/m² toabout 80 g/m² and/or from about 20 g/m² to about 60 g/m².

[0059] The TAD fibrous structures of the present invention and/or paperproducts comprising such TAD fibrous structures may have a total drytensile of greater than about 150 g/in and/or from about 200 g/in toabout 1000 g/in and/or from about 250 g/in to about 850 g/in.

[0060] The TAD fibrous structures of the present invention and/or paperproducts comprising such TAD fibrous structures may have a wet burststrength of greater than about 25 g/in and/or from about 30 g/in toabout 200 g/in and/or from about 150 g/in to about 500 g/in.

[0061] Short Fibers:

[0062] The short fibers of the present invention may have a length offrom about 0.4 mm to about 1.2 mm and/or from about 0.5 mm to about 0.75mm and/or from about 0.6 mm to about 0.7 mm and a coarseness of fromabout 3.0 mg/100 m to about 7.5 mg/100 m and/or from about 5.0 mg/100 mto about 7.5 mg/100 m and/or from about 6.0 mg/100 m to about 7.0 mg/100m.

[0063] The short fibers of the present invention may be derived from afiber source selected from the group consisting of Acacia, Eucalyptus,Maple, Oak, Aspen, Birch, Cottonwood, Alder, Ash, Cherry, Elm, Hickory,Poplar, Gum, Walnut, Locust, Sycamore, Beech, Catalpa, Sassafras,Gmelina, Albizia, Anthocephalus, Magnolia, Bagasse, Flax, Hemp, Kenafand mixtures thereof.

[0064] In one embodiment, the short fibers are derived from tropicalhardwood.

[0065] In another embodiment, the short fibers are derived from a fibersource selected from the group consisting of Acacia, Eucalyptus, Gmelinaand mixtures thereof.

[0066] In another embodiment, the short fibers are derived from a fibersource selected from the group consisting of Acacia, Gmelina andmixtures thereof.

[0067] In yet another embodiment, the short fibers are derived fromAcacia.

[0068] Nonlimiting examples of suitable short fibers having a length offrom about 0.4 mm to about 1.2 mm and a coarseness of from about 3.0mg/100 m to about 7.5 mg/100 m are commercially available from PT Tel ofIndonesia.

[0069] The short fibers of the present invention may comprise celluloseand/or hemicellulose. Preferably, the fibers comprise cellulose.

[0070] The length and coarseness of the short fibers may be determinedusing a Kajaani FiberLab Fiber Analyzer commercially available fromMetso Automation, Kajaani Finland. As used herein, fiber length isdefined as the “length weighted average fiber length”. The instructionssupplied with the unit detail the formula used to arrive at thisaverage. However, the recommended method used to determine fiber lengthsand coarseness of fiber specimens essentially the same as detailed bythe manufacturer of the Fiber Lab. The recommended consistencies forcharging to the Fiber Lab are somewhat lower than recommended by themanufacturer since this gives more reliable operation. Short fiberfurnishes, as defined herein, should be diluted to 0.02-0.04% prior tocharging to the instrument. Long fiber furnishes, as defined herein,should be diluted to 0.15%-0.30%. Alternatively, the length andcoarseness of the short fibers may be determined by sending the shortfibers to an outside contract lab, such as Integrated Paper Services,Appleton, Wisconsin.

[0071] Permanent Wet Strength Resins

[0072] The TAD fibrous structure of the present invention may comprise apermanent wet strength resin. The permanent wet strength resin may bepresent in the fibrous furnish, particularly, the short fiber furnishused to form the TAD fibrous structure and/or can be deposited onto theembryonic fibrous web prior to through-air drying of the embryonicfibrous web.

[0073] The permanent wet strength resins act to control Tinting and alsoto offset the loss in tensile strength, if any, resulting from the anychemical softeners added to the fibrous structure. Further, thepermanent wet strength resins give the fibrous structure or paperproduct it is incorporated into a property such that when it is placedin an aqueous medium it retains a substantial portion of its initial wetstrength over time

[0074] Nonlimiting examples of permanent wet strength resins include:polyamide-epichlorohydrin resins, polyacrylamide resins,styrenebutadiene resins; insolubilized polyvinyl alcohol resins;urea-formaldehyde resins; polyethyleneimine resins; chitosan resins andmixtures thereof. Preferably, the permanent wet strength resins areselected from the group consisting of polyamide-epichlorohydrin resins,polyacrylamide resins and mixtures thereof.

[0075] Polyamide-epichlorohydrin resins are cationic wet strength resinswhich have been found to be of particular utility. Suitable types ofsuch resins are described in U.S. Pat. No. 3,700,623, issued on Oct. 24,1972, and U.S. Pat. No. 3,772,076, issued on Nov. 13, 1973, both issuedto Keim and both being hereby incorporated by reference. One commercialsource of a useful polyamide-epichlorohydrin resins is Hercules, Inc. ofWilmington, Del., which markets such resin under the trade-mark KYMENE®557H.

[0076] Polyacrylamide resins have also been found to be of utility aswet strength resins. These resins are described in U.S. Pat. No.3,556,932, issued on Jan. 19, 1971, to Coscia, et al. and U.S. Pat. No.3,556,933, issued on Jan. 19, 1971, to Williams et al., both patentsbeing incorporated herein by reference. One commercial source ofpolyacrylamide resins is CYTEC Co. of Stanford, Conn., which markets onesuch resin under the trade-mark PAREZ® 631 NC. Still other water-solublecationic resins finding utility in this invention are urea formaldehydeand melamine formaldehyde resins.

[0077] Chemical Softeners:

[0078] The TAD fibrous structure of the present invention may comprise achemical softener.

[0079] As used herein, the term “chemical softener” and/or “chemicalsoftening agent” refers to any chemical ingredient which improves thetactile sensation perceived by the user whom holds a particular paperproduct and rubs it across her skin. Although somewhat desirable fortowel products, softness is a particularly important property for facialand toilet tissues. Such tactile perceivable softness can becharacterized by, but is not limited to, friction, flexibility, andsmoothness, as well as subjective descriptors, such as a feeling likelubricious, velvet, silk or flannel.

[0080] Chemical softening agent is any chemical ingredient which impartsa lubricious feel to tissue. This includes, for exemplary purposes only,basic waxes such as paraffin and beeswax and oils such as mineral oiland silicone oils and silicone gels as well as petrolatum and morecomplex lubricants and emollients such as quaternary ammonium compoundswith long (C10-C22) hydrocarbyl chains, functional silicones, and long(C10-C22) hydrocarbyl chain-bearing compounds possessing functionalgroups such as amines, acids, alcohols and esters.

[0081] The field of work in the prior art pertaining to chemicalsofteners has taken two paths. The first path is characterized by theaddition of softeners to the tissue paper web during its formationeither by adding an attractive ingredient to the vats of pulp which willultimately be formed into a tissue paper web, to the pulp slurry as itapproaches a paper making machine, or to the wet web as it resides on aFourdrinier cloth or dryer cloth on a paper making machine.

[0082] The second path is categorized by the addition of chemicalsofteners to tissue paper web after the web is partially or completelydried. Applicable processes can be incorporated into the paper makingoperation as, for example, by spraying onto the embryonic web and/ordried fibrous structure before it is wound into a roll of paper,extruding, especially via slot extrusion, onto the embryonic web and/ordried fibrous structure, and/or by gravure printing onto the embryonicweb and/or dried fibrous structure.

[0083] Exemplary art related to the former path categorized by addingchemical softeners to the tissue paper prior to its assembly into a webincludes U.S. Pat. No. 5,264,082 issued to Phan and Trokhan on Nov. 23,1993, incorporated herein by reference. Such methods have found broaduse in the industry especially when it is desired to reduce the strengthwhich would otherwise be present in the paper and when the papermakingprocess, particularly the creping operation, is robust enough totolerate incorporation of the bond inhibiting agents.

[0084] Further exemplary art related to the addition of chemicalsofteners to the tissue paper web during its formation includes U.S.Pat. No. 5,059,282 issued to Ampulski, et. al. on Oct. 22, 1991incorporated herein by reference. The Ampulski patent discloses aprocess for adding a polysiloxane compound to a wet tissue web(preferably at a fiber consistency between about 20% and about 35%).Such a method represents an advance in some respects over the additionof chemicals into the slurry vats supplying the papermaking machine. Forexample, such means target the application to one of the web surfaces asopposed to distributing the additive onto all of the fibers of thefurnish.

[0085] Considerable art has been devised to apply chemical softeners toalready-dried paper webs either at the so-called dry end of thepapermaking machine or in a separate converting operation subsequent tothe papermaking step. Exemplary art from this field includes U.S. Pat.No. 5,215,626 issued to Ampulski, et. al. on Jun. 1, 1993; U.S. Pat. No.5,246,545 issued to Ampulski, et. al. on Sep. 21, 1993; and U.S. Pat.No. 5,525,345 issued to Warner, et. al. on Jun. 11, 1996, allincorporated herein by reference. The U.S. Pat. No. 5,215,626 disclosesa method for preparing soft tissue paper by applying a polysiloxane to adry web. The U.S. Pat. No.5,246,545 Patent discloses a similar methodutilizing a heated transfer surface. Finally, the Warner Patentdiscloses methods of application including roll coating and extrusionfor applying particular compositions to the surface of a dry tissue web.

[0086] Particularly preferred chemical softening ingredients are furtherdetailed as follows:

i. Quaternary Ammonium Softeners

[0087] Preferably, quaternary ammonium compounds suitable to serve aschemical softening agents of the present invention have the formula:

(R¹)_(4−m)—N+—[R²]_(m) X⁻

[0088] wherein:

[0089] m is 1 to 3; each R¹ is independently a C₁-C₆ alkyl group,hydroxyalkyl group, hydrocarbyl or substituted hydrocarbyl group,alkoxylated group, benzyl group, or mixtures thereof; each R² isindependently a C₁₄-C₂₂ alkyl group, hydroxyalkyl group, hydrocarbyl orsubstituted hydrocarbyl group, alkoxylated group, benzyl group, ormixtures thereof; and X⁻ is any softener-compatible anion are suitablefor use in the present invention.

[0090] Preferably, each R¹ is methyl and X⁻ is chloride or methylsulfate. Preferably, each R² is independently C₁₆-C₁₈ alkyl or alkenyl,most preferably each R² is independently straight-chain C₁₈ alkyl oralkenyl.

[0091] Particularly preferred variants of these softening agents arewhat are considered to be mono or diester variations of these quaternaryammonium compounds having the formula:

(R¹)_(4−m)—N+—[(CH₂)_(n)—Y—R³]_(m) X⁻

[0092] wherein:

[0093] Y is —O—(O)C—, or —C(O)—O—, or —NH—C(O)—, or —C(O)—NH—; m is 1 to3; n is 0 to 4; each R¹ is independently a C₁-C₆ alkyl group,hydroxyalkyl group, hydrocarbyl or substituted hydrocarbyl group,alkoxylated group, benzyl group, or mixtures thereof; each R³ isindependently a C₁₃-C₂₁ alkyl group, hydroxyalkyl group, hydrocarbyl orsubstituted hydrocarbyl group, alkoxylated group, benzyl group, ormixtures thereof, and X⁻ is any softener-compatible anion.

[0094] Preferably, Y is —O—(O)C—, or —C(O)—O—; m=2; and n=2. Each R¹ isindependently preferably a C₁-C₃, alkyl group, with methyl being mostpreferred. Preferably, each R³ is independently C₁₃-C₁₇ alkyl and/oralkenyl, more preferably R³ is independently straight chain C₁₅-C₁₇alkyl and/or alkenyl, C₁₅-C₁₇ alkyl, most preferably each R³ isindependently straight-chain C₁₇ alkyl.

[0095] As mentioned above, X⁻ can be any softener-compatible anion, forexample, acetate, chloride, bromide, methyl sulfate, formate, sulfate,nitrate and the like can also be used in the present invention.Preferably X⁻ is chloride or methyl sulfate.

[0096] One particularly preferred material is so-called DEEDMAMS(diethyl ester dimethyl ammonium methyl sulfate), further defined hereinwherein the hydrocarbyl chains are derived from tallow fatty acidsoptionally partially hardened to an iodine value from about 10 to about60.

ii. Emollient Lotion Composition

[0097] Suitable chemical softening agents as defined herein may includeemollient lotion compositions. As used herein, an “emollient lotioncomposition” is a chemical softening agent that softens, soothes,supples, coats, lubricates, or moisturizes the skin. An emollienttypically accomplishes several of these objectives such as soothing,moisturizing, and lubricating the skin.

[0098] Emollients useful in the present invention can bepetroleum-based, fatty acid ester type, alkyl ethoxylate type, ormixtures of these emollients. Suitable petroleum-based emollientsinclude those hydrocarbons, or mixtures of hydrocarbons, having chainlengths of from 16 to 32 carbon atoms. Petroleum based hydrocarbonshaving these chain lengths include mineral oil (also known as “liquidpetrolatum”) and petrolatum (also known as “mineral wax,” “petroleumjelly” and “mineral jelly”). Mineral oil usually refers to less viscousmixtures of hydrocarbons having from 16 to 20 carbon atoms. Petrolatumusually refers to more viscous mixtures of hydrocarbons having from 16to 32 carbon atoms. Petrolatum is a particularly preferred emollient foruse in fibrous structures that are incorporated into toilet tissueproducts, and a suitable material is available from Witco, Corp.,Greenwich, Conn. as White Protopet® IS. Mineral oil is also a preferredemollient for use in fibrous structures that are incorporated intofacial tissue products. Such mineral oil is commercially available alsofrom Witco Corp.

[0099] Suitable fatty acid ester type emollients include those derivedfrom C₁₂-C₂₈ fatty acids, preferably C₁₆-C₂₂ saturated fatty acids, andshort chain (C₁-C₈, preferably C₁-C₃) monohydric alcohols.Representative examples of such esters include methyl palmitate, methylstearate, isopropyl laurate, isopropyl myristate, isopropyl palmitate,and ethylhexyl palmitate. Suitable fatty acid ester emollients can alsobe derived from esters of longer chain fatty alcohols (C₁₂-C₂₈,preferably C₁₂-C₁₆) and shorter chain fatty acids e.g., lactic acid,such as lauryl lactate and cetyl lactate.

[0100] Suitable alkyl ethoxylate type emollients include C₁₂-C₁₈ fattyalcohol ethoxylates having an average of from 3 to 30 oxyethylene units,preferably from about 4 to about 23. Representative examples of suchalkyl ethoxylates include laureth-3 (a lauryl ethoxylate having anaverage of 3 oxyethylene units), laureth-23 (a lauryl ethoxylate havingan average of 23 oxyethylene units), ceteth-10 (acetyl ethoxylate havingan average of 10 oxyethylene units) and steareth-10 (a stearylethoxylate having an average of 10 oxyethylene units). These alkylethoxylate emollients are typically used in combination with thepetroleum-based emollients, such as petrolatum, at a weight ratio ofalkyl ethoxylate emollient to petroleum-based emollient of from about1:1 to about 1:3, preferably from about 1:1.5 to about 1:2.5.

[0101] Emollient lotion compositions may optionally include an“immobilizing agents”, so-called because it is believed to act toprevent migration of the emollient so that it can remain primarily onthe surface of the paper structure to which it is applied so that it maydeliver maximum softening benefit as well as be available fortransferability to the users skin. Suitable immobilizing agents for thepresent invention can comprise polyhydroxy fatty acid esters,polyhydroxy fatty acid amides, and mixtures thereof. To be useful asimmobilizing agents, the polyhydroxy moiety of the ester or amide has tohave at least two free hydroxy groups. It is believed that these freehydroxy groups are the ones that co-crosslink through hydrogen bondswith the cellulosic fibers of the tissue paper web to which the lotioncomposition is applied and homo-crosslink, also through hydrogen bonds,the hydroxy groups of the ester or amide, thus entrapping andimmobilizing the other components in the lotion matrix. Preferred estersand amides will have three or more free hydroxy groups on thepolyhydroxy moiety and are typically nonionic in character. Because ofthe skin sensitivity of those using paper products to which the lotioncomposition is applied, these esters and amides should also berelatively mild and non-irritating to the skin.

[0102] Suitable polyhydroxy fatty acid esters for use in the presentinvention will have the formula:

[0103] wherein R is a C₅-C₃₁ hydrocarbyl group, preferably straightchain C₇-C₁₉ alkyl or alkenyl, more preferably straight chain C₉-C₁₇alkyl or alkenyl, most preferably straight chain C₁₁-C₁₇ alkyl oralkenyl, or mixture thereof; Y is a polyhydroxyhydrocarbyl moiety havinga hydrocarbyl chain with at least 2 free hydroxyls directly connected tothe chain; and n is at least 1. Suitable Y groups can be derived frompolyols such as glycerol, pentaerythritol; sugars such as raffinose,maltodextrose, galactose, sucrose, glucose, xylose, fructose, maltose,lactose, mannose and erythrose; sugar alcohols such as erythritol,xylitol, malitol, mannitol and sorbitol; and anhydrides of sugaralcohols such as sorbitan.

[0104] One class of suitable polyhydroxy fatty acid esters for use inthe present invention comprises certain sorbitan esters, preferably thesorbitan esters of C₁₆-C₂₂ saturated fatty acids. Because of the mannerin which they are typically manufactured, these sorbitan esters usuallycomprise mixtures of mono-, di-, tri-, etc. esters. Representativeexamples of suitable sorbitan esters include sorbitan palmitates (e.g.,SPAN 40), sorbitan stearates (e.g., SPAN 60), and sorbitan behenates,that comprise one or more of the mono-, di- and tri-ester versions ofthese sorbitan esters, e.g., sorbitan mono-, di- and tri-palmitate,sorbitan mono-, di- and tri-stearate, sorbitan mono-, di andri-behenate, as well as mixed tallow fatty acid sorbitan mono-, di- andtri-esters. Mixtures of different sorbitan esters can also be used, suchas sorbitan palmitates with sorbitan stearates. Particularly preferredsorbitan esters are the sorbitan stearates, typically as a mixture ofmono-, di- and tri-esters (plus some tetraester) such as SPAN 60, andsorbitan stearates sold under the trade name GLYCOMUL-S by Lonza, Inc.Although these sorbitan esters typically contain mixtures of mono-, di-and tri-esters, plus some tetraester, the mono-and di-esters are usuallythe predominant species in these mixtures.

iii. Polysiloxanes and/or Other Silicone Materials

[0105] Other suitable chemical softening agents suitable for theinvention include silicone materials, such as polysiloxane compounds,cationic silicones, quaternary silicone compounds and/or aminosilicones.In general, suitable polysiloxane materials for use in the presentinvention include those having monomeric siloxane units of the followingstructure:

[0106] wherein, R¹ and R2, for each independent siloxane monomeric unitcan each independently be hydrogen or any alkyl, aryl, alkenyl, alkaryl,arakyl, cycloalkyl, halogenated hydrocarbon, or other radical. Any ofsuch radicals can be substituted or unsubstituted. R¹ and R² radicals ofany particular monomeric unit may differ from the correspondingfunctionalities of the next adjoining monomeric unit. Additionally, thepolysiloxane can be either a straight chain, a branched chain or have acyclic structure. The radicals R¹ and R² can additionally independentlybe other silaceous functionalities such as, but not limited tosiloxanes, polysiloxanes, silanes, and polysilanes. The radicals R¹ andR² may contain any of a variety of organic functionalities including,for example, alcohol, carboxylic acid, phenyl, and aminefunctionalities.

[0107] Exemplary alkyl radicals are methyl, ethyl, propyl, butyl,pentyl, hexyl, octyl, decyl, octadecyl, and the like. Exemplary alkenylradicals are vinyl, allyl, and the like. Exemplary aryl radicals arephenyl, diphenyl, naphthyl, and the like. Exemplary alkaryl radicals aretoyl, xylyl, ethylphenyl, and the like. Exemplary aralkyl radicals arebenzyl, alpha-phenylethyl, beta-phenylethyl, alpha-phenylbutyl, and thelike. Exemplary cycloalkyl radicals are cyclobutyl, cyclopentyl,cyclohexyl, and the like. Exemplary halogenated hydrocarbon radicals arechloromethyl, bromoethyl, tetrafluorethyl, fluorethyl, trifluorethyl,trifluorotloyl, hexafluoroxylyl, and the like.

[0108] Preferred polysiloxanes include straight chain organopolysiloxanematerials of the following general formula:

[0109] wherein each R¹-R⁹ radical can independently be any C₁-C₁₀unsubstituted alkyl or aryl radical, and R₁₀ of any substituted C₁-C₁₀alkyl or aryl radical. Preferably each R¹-R⁹ radical is independentlyany C₁-C₄ unsubstituted alkyl group, those skilled in the art willrecognize that technically there is no difference whether, for example,R⁹ or R₁₀ is the substituted radical. Preferably the mole ratio of b to(a+b) is between 0 and about 20%, more preferably between 0 and about10%, and most preferably between about 1% and about 5%.

[0110] In one particularly preferred embodiment, R¹-R⁹ are methyl groupsand R₁₀ is a substituted or unsubstituted alkyl, aryl, or alkenyl group.Such material shall be generally described herein aspolydimethylsiloxane which has a particular functionality as may beappropriate in that particular case. Exemplary polydimethylsiloxaneinclude, for example, polydimethylsiloxane having an alkyl hydrocarbonR¹⁰ radical and polydimethylsiloxane having one or more amino, carboxyl,hydroxyl, ether, polyether, aldehyde, ketone, amide, ester, thiol,and/or other functionalities including alkyl and alkenyl analogs of suchfunctionalities. For example, an amino functional alkyl group as R¹⁰could be an amino functional or an aminoalkyl-functionalpolydimethylsiloxane. The exemplary listing of thesepolydimethylsiloxanes is not meant to thereby exclude others notspecifically listed.

[0111] Viscosity of polysiloxanes useful for this invention may vary aswidely as the viscosity of polysiloxanes in general vary, so long as thepolysiloxane can be rendered into a form which can be applied to thetissue paper product herein. This includes, but is not limited to,viscosity as low as about 25 centistokes to about 20,000,000 centistokesor even higher.

[0112] While not wishing to be bound by theory, it is believed that thetactile benefit efficacy is related to average molecular weight and thatviscosity is also related to average molecular weight. Accordingly, dueto the difficulty of measuring molecular weight directly, viscosity isused herein as the apparent operative parameter with respect toimparting softness to tissue paper.

[0113] References disclosing polysiloxanes include U.S. Pat. No.2,826,551, issued to Geen on Mar. 11, 1958; U.S. Pat. No. 3,964,500,issued to Drakoff on Jun. 22, 1976; U.S. Pat. No. 4,364,837, issued toPader on Dec. 21, 1982; U.S. Pat. No. 5,059,282, issued to Ampulski;U.S. Pat. No. 5,529,665 issued to Kaun on Jun. 25, 1996; U.S. Pat. No.5,552,020 issued to Smithe et al. on Sep. 3, 1996; and British Patent849,433, published on Sep. 28, 1960 in the name of Wooston. All of thesepatents are incorporated herein by reference. Also incorporated hereinby reference is Silicone Compounds, pp. 181-217, distributed by PetrachSystems, Inc., which contains an extensive listing and description ofpolysiloxanes in general.

[0114] In one embodiment, the chemical softeners may be mixed with thefibers, especially the short fibers to form the fibrous furnish,especially the short fiber furnish.

[0115] In another embodiment, the chemical softeners may be applied tothe embryonic fibrous web and/or the TAD fibrous structure. Applicationof the chemical softener to the embryonic fibrous web and/or TAD fibrousstructure may be by any suitable process known to those of ordinaryskill in the art. Nonlimiting examples of such application processesinclude spraying the chemical softener onto the embryonic fibrous weband/or TAD fibrous structure and/or extruding the chemical softener ontothe embryonic fibrous web and/or TAD fibrous structure. Otherapplication processes include brushing the chemical softener onto theembryonic fibrous web and/or TAD fibrous structure and/or dipping theembryonic fibrous web and/or TAD fibrous structure in the chemicalsoftener.

[0116] Optional Ingredients:

[0117] The TAD fibrous structure of the present invention may comprisean optional ingredient selected from the group consisting of temporarywet strength resins, dry strength resins, wetting agents, lint resistingagents, absorbency-enhancing agents, immobilizing agents, especially incombination with emollient lotion compositions, antiviral agentsincluding organic acids, antibacterial agents, polyol polyesters,antimigration agents, polyhydroxy plasticizers and mixtures thereof.Such optional ingredients may be added to the fiber furnish, theembryonic fibrous web and/or the TAD fibrous structure.

[0118] Such optional ingredients may be present in the TAD fibrousstructure at any level based on the dry weight of the TAD fibrousstructure.

[0119] The optional ingredients may be present in the TAD fibrousstructure at a level of from about 0.001 to about 50% and/or from about0.001 to about 20% and/or from about 0.01 to about 5% and/or from about0.03 to about 3% and/or from about 0.1 to about 1.0% by weight, on a dryTAD fibrous structure basis.

i. Temporary Wet Strength Additives

[0120] One method of delivering fugitive wet strength is to provide forthe formation of acid-catalysed hemiacetal formation through theintroduction of ketone or, more specifically aldehyde functional groupson the papermaking fibers or in a binder additive for the papermakingfibers. One binder material that have been found particularly useful forimparting this form of fugitive wet strength is Parez 750 offered byCytec of Stamford, Conn.

[0121] Other additives can also be used to augment this wet strengthmechanism. This technique for delivering fugitive wet strength is wellknown in the art. Exemplary art, incorporated herein by reference forthe purpose of showing methods of delivering the fugitive wet strengthto the web, includes the following U.S. Pat. Nos. 5,690,790; 5,656,746;5,723,022; 4,981,557; 5,008,344; 5,085,736; 5,760,212; 4,605,702;6,228,126; 4,079,043; 4,035,229; 4,079,044; and 6,127,593.

[0122] While the hemiacetal formation mechanism is one suitabletechnique for generating temporary wet strength, there are othermethods, such as providing the sheet with a binder mechanism which ismore active in the dry or slightly wet condition than in the conditionof high dilution as would be experienced in the toilet bowl or in thesubsequent sewer and septic system. Such methods have been primarilydirected at web products which are to be delivered in a slightly moistor wet condition, then will be disposed under situation of highdilution. The following references are incorporated herein by referencefor the purpose of showing exemplary systems to accomplish this, andthose skilled in the art will readily recognize that they can be appliedto the webs of the present invention which will be supplied generally atlower moisture content than those described therewithin: U.S. Pat. Nos.4,537,807; 4,419,403; 4,309,469; and 4,362,781.

ii. Dry Strength Additives

[0123] Nonlimiting examples of dry strength resins includepolyacrylamides (such as combinations of CYPRO 514 and ACCOSTRENGTH 711produced by Cytec of Stamford Conn.; starch, for example corn starchand/or potato starch (such as REDIBOND 5320 and 2005) available fromNational Starch and Chemical Company, Bridgewater, N.J.; polyvinylalcohol (such as AIRVOL® 540 produced by Air Products Inc of Allentown,Pa.); guar or locust bean gums; and/or carboxymethyl cellulose (such asCMC from Hercules, Inc. of Wilmington, Del.). Dry strength additives areused in more or less amounts to control tensile strength and lintlevels.

iii. Wetting Agents

[0124] Nonlimiting examples of wetting agents suitable for use in thepresent invention include polyhydroxy compounds, such as glyercol andpolyglycols, and nonionic surfactants, such as addition products ofethylene oxide and, optionally, propylene oxide, with fatty alcohols,fatty acids and fatty amines.

[0125] The above listing of optional ingredients is intended to bemerely exemplary in nature, and is not meant to limit the scope of theinvention.

[0126] Processes of the Present Invention:

[0127] The TAD fibrous structure of the present invention may be made byany suitable TAD papermaking process.

[0128] A nonlimiting example of a suitable TAD papermaking process formaking the TAD fibrous structure of the present invention is describedas follows.

[0129] In one embodiment, a short fiber furnish is prepared by mixing ashort fiber with water. One or more additional ingredients such as aphysical property ingredient and/or optional ingredients may be added tothe short fiber furnish. The short fiber furnish may then be put into aheadbox of a papermaking machine. The short fiber furnish may then bedeposited on a foraminous surface to form a single layer embryonicfibrous web. Physical property ingredients and/or optional ingredientsmay be added to the embryonic fibrous web by spraying and/or extrudingand/or by any other suitable process known to those of ordinary skill inthe art. The embryonic web may then be transferred to a through-airdrying belt such that the embryonic fibrous web is dried via through-airdrying. From the through-air drying belt, the TAD fibrous structure maybe transferred to a Yankee dryer. From the Yankee dryer, the TAD fibrousstructure may be wound into a roll.

[0130] From the through-air drying belt, or after transfer to a Yankeedryer, if such a dryer is employed, the TAD fibrous structure may bewound into a roll. Physical property ingredients and/or optionalingredients may be applied to the TAD fibrous structure while it issemi-dry or after dried completely. The TAD fibrous structure may beconverted into various paper products, particularly sanitary tissueproducts, both in single-ply forms and/or in multi-ply forms.

[0131] In another embodiment, a TAD fibrous structure is prepared from ashort fiber furnish and a long fiber furnish. The long fiber furnish maybe made by mixing a long fiber with water. The long fiber furnish mayinclude one or more additional ingredients such as a physical propertyingredient and/or optional ingredients. These one or more additionalingredients may be present in the long and/or short fiber furnish. Thefibrous furnish may be placed in a layered headbox of a papermakingmachine. The fibrous furnishes may then be deposited on a foraminoussurface to form a multi-layered embryonic fibrous web wherein the longfiber furnish is directed into one or more layers and the short fiberfurnish is directed into one or more layers.

[0132] Preferred layering methodology for structures which will beassembled into two-ply products include two-layered structures whereinthe short fiber furnish is applied into a surface layer, i.e. the layerwhich will be in contact with a user of the product. In this case , thelong fiber furnish layer will be directed toward the inside of thetwo-ply assembly.

[0133] Preferred layering methodology for structures which will beconverted into single-ply products include three-layered structureswherein the short fiber furnish is applied into the surface layerssurrounding a central long fibered layer.

[0134] Physical property ingredients and/or optional ingredients may beadded to the embryonic fibrous web by spraying and/or extruding and/orby any other suitable process known to those of ordinary skill in theart. The embryonic web may then be transferred to a through-air dryingbelt such that the embryonic fibrous web is dried via through-airdrying.

[0135] Physical property ingredients and/or optional ingredients may beadded to the semi-dry or dry fibrous web by spraying and/or extrudingand/or by any other suitable process known to those of ordinary skill inthe art.

[0136] From the through-air drying belt, or after transfer to a Yankeedryer, if such a dryer is employed, the TAD fibrous structure may bewound into a roll. Physical property ingredients and/or optionalingredients may be applied to the TAD fibrous structure while it issemi-dry or after dried completely. The TAD fibrous structure may beconverted into various paper products, particularly sanitary tissueproducts, both in single-ply forms and/or in multi-ply forms. The paperproducts may be designed such that the surface of the paper product thatis intended to contact a human's skin comprises a short fiber furnishand/or a short fiber.

EXAMPLE 1

[0137] This Example illustrates a process incorporating a preferredembodiment of the present invention using the pilot scale Fourdrinier tomake a facial tissue product.

[0138] An aqueous slurry of Northern Softwood Kraft (NSK) of about 3%consistency is made up using a conventional pulper and is passed througha stock pipe toward the headbox of the Fourdrinier.

[0139] In order to impart a permanent wet strength to the finishedproduct, a 1% dispersion of Hercules' Kymene 557 LX is prepared and isadded to the NSK stock pipe at a rate sufficient to deliver 0.7% Kymene557 LX based on the dry weight of the ultimate paper. The absorption ofthe permanent wet strength resin is enhanced by passing the treatedslurry through an in-line mixer. Carboxymethyl cellulose (CMC) is addednext to the NSK stock pipe after the in-line mixer. CMC is firstdissolved in water and diluted to a solution strength of 1% by weight.Hercules CMC-7MT® is used to make-up the CMC solution. The aqueoussolution of CMC is added to the aqueous slurry of NSK fibers at a rateof 0.15% CMC by weight based on the dry weight of the ultimate paper.The aqueous slurry of NSK fibers passes through a centrifugal stock pumpto aid in distributing the CMC. The chemical softening composition isadded next. The chemical softening composition is DiTallow DiMethylAmmonium Methyl Sulfate (DTDMAMS). Pre-heated DTDMAMS (170° F.) is firstslurried in water conditioned by pre-heating to 170° F. The water isagitated during addition of the DTDMAMS to aid in its dispersion. Theconcentration of the resultant DTDMAMS dispersion is 1% by weight, andit is added to the NSK stock pipe at a rate of 0.2% by weight DTDMAMSbased on the dry weight of the ultimate paper. The NSK slurry is dilutedwith white water to about 0.2% consistency at the fan pump.

[0140] An aqueous slurry of acacia fibers (from PT Tel-Indonesia) ofabout 3% by weight is made up using a conventional repulper. The Acaciafurnish has a weighted average fiber length of 0.66 mm and a coarsenessof 7.1 mg/100 m. The Acacia slurry passes to the second fan pump whereit is diluted with white water to a consistency of about 0.2%.

[0141] The slurries of NSK and acacia are directed into amulti-channeled headbox suitably equipped with layering leaves tomaintain the streams as separate layers until discharged onto atraveling Fourdrinier wire. A three-chambered headbox is used. Theacacia slurry containing 64% of the dry weight of the ultimate paper isdirected to the chambers leading to the outer layer, while the NSKslurry comprising 36% of the dry weight of the ultimate paper isdirected to the chamber leading to the layer in contact with the wireand to the central layer. The NSK and acacia slurries are combined atthe discharge of the headbox into a composite slurry.

[0142] The composite slurry is discharged onto the traveling Fourdrinierwire and is dewatered assisted by a deflector and vacuum boxes. Theembryonic wet web is transferred from the Fourdrinier wire, at a fiberconsistency of about 17% by weight at the point of transfer, to apatterned drying fabric. The drying fabric is designed to yield apattern-densified tissue with discontinuous low-density deflected areasarranged within a continuous network of high density (knuckle) areas.This drying fabric is formed by casting an impervious resin surface ontoa fiber mesh supporting fabric. The supporting fabric is a 48×52filament, dual layer mesh. The thickness of the resin cast is about 12mil above the supporting fabric. The knuckle area is about 30% and theopen cells remain at a frequency of about 68 per square inch.

[0143] Further de-watering is accomplished by vacuum assisted drainageuntil the web has a fiber consistency of about 22% by weight. Whileremaining in contact with the patterned forming fabric, the patternedweb is pre-dried by air blow-through pre-dryer to a fiber consistency ofabout 58% by weight.

[0144] The semi-dry web is then adhered to the surface of a Yankee dryerwith a sprayed creping adhesive comprising a 0.250% aqueous solution ofpolyvinyl alcohol. The creping adhesive is delivered to the Yankeesurface at a rate of 0.1% adhesive solids based on the dry weight of theweb.

[0145] The fiber consistency is increased to about 98% before the web isdry creped from the Yankee with a doctor blade. The doctor blade has abevel angle of about 20 degrees and is positioned with respect to theYankee dryer to provide an impact angle of about 76 degrees. The Yankeedryer is operated at a temperature of about 350° F. (177° C.) and aspeed of about 800 fpm (feet per minute) (about 244 meters per minute).The paper is wound in a roll using a surface driven reel drum having asurface speed of about 680 fpm (about 207 meters per minute), thusresulting in a crepe of about 15%.

[0146] After the doctor blade, the web is calendered across all itswidth with a steel to rubber calendar roll operating at a loading of 400psi. Resulting tissue has a basis weight of about 20 g/m2; a 1-ply totaldry tensile between 210 and 240 g/in, a 1-ply wet burst between 35 and65 g/in and a 2-ply caliper of about 0.020 inches. Resulting tissue isthen plied together with a like sheet to form a two-ply, creped, patterndensified tissue so that the acacia fibers face the outside. Theresulting two-ply tissue has a) a total basis weight of about 39 g/m2;b) a 2-ply total dry tensile between 350 and 420 g/in; c) a 2-ply wetburst between 90 and 130 g/in; and d) a 4-ply caliper of about 0.028inches.

EXAMPLE 2

[0147] The same 2-ply, creped, pattern densified tissue, with the acaciafibers facing outside presented in Example #1, adding CM849—an aminofunctional dimethyl polysiloxane sold by General Electric Silicones ofWaterford, N.Y.—via slot extrusion onto both sides in contact with ahuman's skin, at an add-on amount of approximately 0.3-0.5 percent ofsilicone per ply based on the total weight of fibers. A comparativeproduct is made in the same manner as this example except that aEucalyptus bleached kraft fibrous pulp is substituted for the Acaciableached kraft fibrous pulp. The Eucalyptus pulp furnish has a fiberlength of 0.73 mm and a coarseness of 8.0 mg/100 m. The resultant tissuepaper using the comparative furnish is judged less soft by a panel ofexpert judges.

EXAMPLE 3

[0148] This Example illustrates another process incorporating apreferred embodiment of the present invention using the pilot scaleFourdrinier to make a facial tissue product. An aqueous slurry ofNorthern Softwood Kraft (NSK) of about 3% consistency is made up using aconventional pulper and is passed through a stock pipe toward theheadbox of the Fourdrinier.

[0149] In order to impart a permanent wet strength to the finishedproduct, a 1% dispersion of Hercules' Kymene 557 LX is prepared and isadded to the NSK stock pipe at a rate sufficient to deliver 0.9% Kymene557 LX based on the dry weight of the ultimate paper. The absorption ofthe permanent wet strength resin is enhanced by passing the treatedslurry through an in-line mixer. Carboxymethyl cellulose (CMC) is addednext to the NSK stock pipe after the in-line mixer. CMC is firstdissolved in water and diluted to a solution strength of 1% by weight.Hercules CMC-7MT® is used to make-up the CMC solution. The aqueoussolution of CMC is added to the aqueous slurry of NSK fibers at a rateof 0.15% CMC by weight based on the dry weight of the ultimate paper.The aqueous slurry of NSK fibers passes through a centrifugal stock pumpto aid in distributing the CMC. The bonding inhibitor composition isadded next. The bonding inhibitor composition is DiTallow DiMethylAmmonium Methyl Sulfate (DTDMAMS). Pre-heated DTDMAMS (170° F.) is firstslurried in water conditioned by pre-heating to 170° F. The water isagitated during addition of the DTDMAMS to aid in its dispersion. Theconcentration of the resultant DTDMAMS dispersion is 1% by weight, andit is added to the NSK stock pipe at a rate of 0.125% by weight DTDMAMSbased on the dry weight of the ultimate paper.

[0150] An aqueous slurry of acacia fibers (from PT Tel-Indonesia) ofabout 1.5% by weight is made up using a conventional repulper and ispassed through a stock pipe toward the headbox of the Fourdrinier. TheAcacia furnish has a weighted average fiber length of 0.66 mm and acoarseness of 7.1 mg/100 m. This Acacia furnish joins the NSK slurry atthe fan pump where both are diluted with white water to about 0.2%consistency.

[0151] An aqueous slurry of acacia fibers (from PT Tel-Indonesia) ofabout 3% by weight is made up using a conventional repulper. The Acaciaslurry passes to the second fan pump where it is diluted with whitewater to a consistency of about 0.2%.

[0152] The slurries of NSK/acacia and acacia are directed into amulti-channeled headbox suitably equipped with layering leaves tomaintain the streams as separate layers until discharged onto atraveling Fourdrinier wire. A three-chambered headbox is used. Theacacia slurry containing 53% of the dry weight of the ultimate paper isdirected to the chambers leading to the outer layer, while theNSK/acacia slurry comprising 47% (30% NSK and 17% acacia) of the dryweight of the ultimate paper is directed to the chamber leading to thelayer in contact with the wire and to the chamber leading to the layerbetween the outer layer and the layer in contact with the wire. TheNSK/acacia and acacia slurries are combined at the discharge of theheadbox into a composite slurry.

[0153] The composite slurry is discharged onto the traveling Fourdrinierwire and is dewatered assisted by a deflector and vacuum boxes. Theembryonic wet web is transferred from the Fourdrinier wire, at a fiberconsistency of about 18% by weight at the point of transfer, to apatterned drying fabric. The drying fabric is designed to yield apattern-densified tissue with discontinuous low-density deflected areasarranged within a continuous network of high density (knuckle) areas.This drying fabric is formed by casting an impervious resin surface ontoa fiber mesh supporting fabric. The supporting fabric is a 48×52filament, dual layer mesh. The thickness of the resin cast is about 9mil above the supporting fabric. The knuckle area is about 40% and theopen cells remain at a frequency of about 68 per square inch.

[0154] Further de-watering is accomplished by vacuum assisted drainageuntil the web has a fiber consistency of about 26%. While remaining incontact with the patterned forming fabric, the patterned web ispre-dried by air blown through to a fiber consistency of about 59% byweight.

[0155] The semi-dry web is then adhered to the surface of a Yankee dryerwith a sprayed creping adhesive comprising a 0.250% aqueous solution ofpolyvinyl alcohol. The creping adhesive is delivered to the Yankeesurface at a rate of 0.1% adhesive solids based on the dry weight of theweb.

[0156] The fiber consistency is increased to about 98% before the web isdry creped from the Yankee with a doctor blade. The doctor blade has abevel angle of about 20 degrees and is positioned with respect to theYankee dryer to provide an impact angle of about 76 degrees. The Yankeedryer is operated at a temperature of about 300° F. and a speed of about800 fpm (feet per minute) (about 244 meters per minute). The paper iswound in a roll using a surface driven reel drum having a surface speedof about 680 fpm (about 207 meters per minute), thus resulting in acrepe of about 15%.

[0157] After the doctor blade, the web is calendared across all itswidth with a steel to rubber calendar roll operating at a loading of 450psi.

[0158] Resulting tissue has a basis weight of about 22 g/m2; a 1-plytotal dry tensile between 280 and 320 g/in, a 1-ply wet burst between 45and 65 g/in and a 2-ply caliper of about 0.020 inches.

[0159] Resulting tissue is then plied together with a like sheet to forma two-ply, creped, pattern densified tissue so that the acacia fibersface the outside. The resulting two-ply tissue has a) a total basisweight of about 42-45 g/m2; b) a 2-ply total dry tensile between 550 and600 g/in; c) a 2-ply wet burst between 90 and 120 g/in; and d) a 4-plycaliper of about 0.028 inches.

EXAMPLE 4

[0160] This Example illustrates a process incorporating a preferredembodiment of the present invention using the pilot scale Fourdrinier tomake a toilet tissue product. An aqueous slurry of Northern SoftwoodKraft (NSK) of about 3% consistency is made up using a conventionalpulper and the furnish is passed through a stock pipe toward the headboxof the Fourdrinier.

[0161] In order aid in delivering a temporary wet strength to thefinished product, a 1% dispersion of Cytec's Parez 750C is prepared andis added to the NSK stock pipe at a rate sufficient to deliver 0.2% ofthe resin based on the dry weight of the ultimate paper. The absorptionof the temporary wet strength resin is enhanced by passing the treatedslurry through an in-line mixer.

[0162] The NSK slurry furnish is diluted with white water to about 0.2%consistency at the fan pump.

[0163] An aqueous slurry of Acacia bleached kraft fibrous pulp (from PTTel-Indonesia) of about 3% by weight is made up using a conventionalrepulper and the furnish is passed through a stock pipe toward theheadbox of the Fourdrinier. The Acacia furnish has a weighted averagefiber length of 0.66 mm and a coarseness of 7.1 mg/100 m. In order toaid in delivering temporary wet strength to the finished product, the 1%dispersion of Cytec's Parez 750C is also added to the Acacia stock pipeat a rate sufficient to deliver 0.05% of the resin based on the dryweight of the ultimate paper. The absorption of the temporary wetstrength resin is enhanced by passing the treated slurry through anin-line mixer. The Acacia slurry furnish passes to the second fan pumpwhere it is diluted with white water to a consistency of about 0.2%.

[0164] The slurries of NSK and acacia are directed into amulti-channeled headbox suitably equipped with layering leaves tomaintain the streams as separate layers until discharged onto atraveling Fourdrinier wire. A three-chambered headbox is used. Theacacia slurry containing 70% of the dry weight of the ultimate paper isdirected to the chambers leading to the outer layers, while the NSKslurry comprising 30% of the dry weight of the ultimate paper isdirected to the chamber leading to the central layer.

[0165] The NSK and acacia slurries are combined at the discharge of theheadbox into a composite slurry and the composite slurry is dischargedonto the traveling Fourdrinier wire and is dewatered assisted by adeflector and vacuum boxes.

[0166] The embryonic wet web is transferred from the Fourdrinier wire,at a fiber consistency of about 15% at the point of transfer, to apatterned drying fabric. The drying fabric is designed to yield apattern-densified tissue with discontinuous low-density deflected areasarranged within a continuous network of high density (knuckle) areas.This drying fabric is formed by casting an impervious resin surface ontoa fiber mesh supporting fabric. The supporting fabric is a 45×52filament, dual layer mesh. The thickness of the resin cast is about 10mil above the supporting fabric. The knuckle area is about 40% and theopen cells remain at a frequency of about 78 per square inch.

[0167] Further de-watering is accomplished by vacuum assisted drainageuntil the web has a fiber consistency of about 30%. While remaining incontact with the patterned forming fabric, the patterned web ispre-dried by air blow-through pre-dryers to a fiber consistency of about65% by weight. The semi-dry web is then transferred to the Yankee dryerand adhered to the surface of the Yankee dryer with a sprayed crepingadhesive comprising a 0.125% aqueous solution of polyvinyl alcohol. Thecreping adhesive is delivered to the Yankee surface at a rate of 0.1%adhesive solids based on the dry weight of the web. The fiberconsistency is increased to about 98% before the web is dry creped fromthe Yankee with a doctor blade.

[0168] The doctor blade has a bevel angle of about 25 degrees and ispositioned with respect to the Yankee dryer to provide an impact angleof about 81 degrees. The Yankee dryer is operated at a temperature ofabout 350° F. (177° C.) and a speed of about 800 fpm (feet per minute)(about 244 meters per minute). The paper is wound in a roll using asurface driven reel drum having a surface speed of about 656 feet perminute. In a free span between the doctor blade and the reel in aposition at which the web is essentially horizontal, an applicatorcomprising an extrusion slot applies an aqueous dispersion of DEEDMAMShaving 44% cationic actives onto the top side of the tissue web suchthat the actives are uniformly distributed onto the tissue web surface.A sufficient flow of the DEEDMAMS slurry is maintained so that 1%DEEDMAMS is applied to the tissue web surface.

[0169] The resulting tissue paper web is converted into a single-plytoilet tissue paper product using a conventional tissue winding stand.The finished product has a basis weight of about 21 lb/3000 ft2; a totaldry tensile of 450 g/in and a density of 0.065 g/cm³. A comparativeproduct is made in the same manner as this example except that aEucalyptus bleached kraft fibrous pulp is substituted for the Acaciableached kraft fiberous pulp. The Eucalyptus pulp furnish has a fiberlength of 0.73 mm and a coarseness of 8.0 mg/100 m. The resultant tissuepaper using the comparative furnish is judged less soft by a panel ofexpert judges.

EXAMPLE 5

[0170] Example 4 is repeated except that the furnish flow rates areadjusted in order to reduce the basis weight of the fibrous web in orderto make a two ply tissue web product. Preparation of the two ply productis completed by simultaneously unwinding two rolls of fibrous webcombining them into a two-ply bath by a narrow, approximately ½″ stripeof pressure sensitive adhesive which allows the plies to maintain theirability to slip relative to one another. The combining is completed sothat the respective Yankee-side surfaces of each ply contact each other.The finished product has a basis weight of about 28 lb/3000 ft2; a totaldry tensile of 500 g/in and a density of 0.055 g/cm³. Again, acomparative product is made in the same manner as this example exceptthat the Eucalyptus bleached kraft fibrous pulp is substituted for theAcacia bleached kraft fibrous pulp. Again, the resultant tissue paperusing the comparative furnish is judged less soft by a panel of expertjudges.

[0171] While particular embodiments and/or individual features of thepresent invention have been illustrated and described, it would beobvious to those skilled in the art that various other changes andmodifications can be made without departing from the spirit and scope ofthe invention. Further, it should be apparent that all combinations ofsuch embodiments and features are possible and can result in preferredexecutions of the invention. Therefore, the appended claims are intendedto cover all such changes and modifications that are within the scope ofthis invention.

What is claimed is:
 1. A through-air dried fibrous structure comprising:a. a short fiber furnish comprising a short fiber having a length offrom about 0.4 mm and about 1.2 mm and a coarseness of from about 3.0mg/100 m to about 7.5 mg/100 m, and b. a physical property ingredientselected from the group consisting of permanent wet strength resins,chemical softeners and mixtures thereof.
 2. The through-air driedfibrous structure according to claim 1 wherein said short fiber furnishcomprises cellulose.
 3. The through-air dried fibrous structureaccording to claim 2 wherein said short fiber furnish is derived from afiber source selected from the group consisting of: Acacia , Eucalyptus,Maple, Oak, Aspen, Birch, Cottonwood , Alder, Ash, Cherry , Elm ,Hickory , Poplar, Gum, Walnut , Locust , Sycamore , Beech , Catalpa ,Sassafras , Gmelina , Albizia , Anthocephalus, Magnolia, Bagasse, Flax,Hemp, Kenaf, and mixtures thereof.
 4. The through-air dried fibrousstructure according to claim 1 wherein the fibrous structure furthercomprises a long fiber furnish comprising a long fiber having a lengthgreater than 1.2 mm.
 5. The through-air dried fibrous structureaccording to claim 4 wherein the fibrous structure comprises at least10% by weight of the total fiber composition of said short fiberfurnish.
 6. The through-air dried fibrous structure according to claim 4wherein the fibrous structure has a basis weight greater than about 12g/m² to about 120 g/m².
 7. The through-air dried fibrous structureaccording to claim 4 wherein the fibrous structure has a total drytensile greater than about 150 g/in and a wet burst strength greaterthan about 25 g/in.
 8. The through-air dried fibrous structure accordingto claim 4 wherein the fibrous structure comprises two or more fibrousfurnish layers.
 9. The through-air dried fibrous structure according toclaim 8 wherein at least one of the two or more fibrous furnish layerscomprises the short fiber furnish.
 10. The through-air dried fibrousstructure according to claim 9 wherein the at least one of the two ormore fibrous furnish layers when incorporated into a sanitary tissueproduct contacts a human's skin upon use.
 11. The through-air driedfibrous structure according to claim 1 wherein said physical propertyingredient comprises a permanent wet strength resin comprising apolyamide-epichlorohydrin resin.
 12. The through-air dried fibrousstructure according to claim 1 wherein said physical property ingredientcomprises a chemical softener selected from a group consisting ofquaternary ammonium compounds, silicones, emollient lotion compounds andmixtures thereof.
 13. The through-air dried fibrous structure accordingto claim 1 wherein the through-air dried fibrous structure furthercomprises an optional ingredient selected from the group consisting of:temporary wet strength resins, dry strength resins, wetting agents, lintresisting agents, absorbency-enhancing agents, immobilizing agents,antiviral agents, antibacterial agents, polyol polyesters, antimigrationagents, polyhydroxy plasticizers and mixtures thereof
 14. A paperproduct comprising a fibrous structure according to claim
 1. 15. Aone-ply sanitary tissue product selected from the group consisting offacial tissue products, toilet tissue products, paper towel products andmixtures thereof comprising a fibrous structure according to claim 1.16. A multi-ply sanitary tissue product selected from the groupconsisting of facial tissue products, toilet tissue products, papertowel products and mixtures thereof, wherein at least one ply of themulti-ply sanitary tissue product comprises a fibrous structureaccording to claim
 1. 17. A process for making a through-air driedfibrous structure comprising the steps of: a. preparing a fibrousfurnish comprising a short fiber furnish comprising a short fiber havinga length of from about 0.4 mm to about 1.2 mm and a coarseness of fromabout 3.0 mg/100 m to about 7.5 mg/100 m, by mixing the short fiber withwater to form the short fiber furnish; b. depositing the fibrous furnishon a foraminous forming surface to form an embryonic fibrous web; c.adding a permanent wet strength resin to the fibrous furnish and/or theembryonic fibrous web; and d. through-air drying said embryonic fibrousweb such that the through-air dried fibrous structure is formed.
 18. Theprocess according to claim 17 wherein the embryonic fibrous web isformed from two or more furnish layers.
 19. A process for making athrough-air dried, chemical softener-containing fibrous structurecomprising the steps of: a. preparing a fibrous furnish comprising ashort fiber furnish comprising a short fiber having a length of fromabout 0.4 mm to about 1.2 mm and a coarseness of from about 3.0 mg/100 mto about 7.5 mg/100 m, by mixing the short fiber with water to form theshort fiber furnish; b. depositing the fibrous furnish on a foraminousforming surface to form an embryonic fibrous web; c. through-air dryingsaid embryonic fibrous web such that through-air dried fibrous structureis formed; and d. applying a chemical softener to the fibrous furnishand/or embryonic fibrous web and/or through-air dried fibrous structuresuch that the through-air dried, chemical softener-containing fibrousstructure is formed.
 20. The process according to claim 19 wherein theembryonic fibrous web is formed from two or more furnish layers.